CS4 - "PProheadless.exe has stopped working"

Hi guys, I'm getting the above error when I export a wedding video I've finished working on, I need a solution ASAP!
I've searched online and tried suggestions everyone's made.
I've done the following:
re-encoded original files and replaced them in the project (audio too), using different codecs and resolutions
set affinity to 1 CPU core
set premiere edit-preferences-general render from performance to memory
closed everything else in processes list that wasn't essential
save to a different HDD
save to different codecs, resolutions, bitrates etc
I can encode other, shorter videos fine (not tried longer). It always stops between 6 & 7 minutes every time.
I have noticed that people who have the problem have the same CPU and OS as me!
I have 3Gb DDR3 RAM, Core i7 920 CPU, ATI HD 3400 gfx and Windows Vista Home Premium SP1 64 bit.
The PC has been restarted numerous times over the last 3 days while trying to sort this, I've updated all drivers from the manufacturers web site (gfx, chipset etc)
I'm stuck for ideas now and am really desperate

Hi Harm -
I'm having the exact same error currently and have just run-through you list of suggestions and am now re-exporting to see if it worked.
I'm curious to know if the "vssadmin" command has to be done every time or is it permanently set each time?
I must admit - even if your solution does fix this problem (..fingers crossed!!!) - that I'm more than a bit frustrated and annoyed that a program
costing this much money (AUD$1400.00) should be this "buggy". I've used much cheaper programs in the past and had nowhere near the problems
I've had since using Premiere.
Please tell me that there's light at the end of the tunnel because right now I wouldn't recommend this to anyone and feel as though I've been duped!
TB

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